LEMON Manuals: Even more car manuals for everyone
Home >> Toyota >> 2004 >> Highlander Limited, FWD >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 20 (Engine Mechanical (2AZ-FE)) >> Cylinder Head Gasket (2AZ-FE) >> Replacement

Cylinder Head Gasket (2AZ-FE): Replacement

WARNING: This page is about a different variant/trim than selected.
  1. WORK FOR PREVENTING GASOLINE FROM SPILLING OUT 
  2. REMOVE FRONT SUSPENSION BRACE SUB-ASSY UPPER CENTER (W/ FRONT SUSPENSION BRACE UPPER CENTER) 
  3. DRAIN COOLANT (See  REPLACEMENT  ) 
  4. DRAIN TRANSFER OIL (4WD TYPE) 
  5. DISCONNECT RADIATOR HOSE OUTLET 
  6. DISCONNECT UNION TO CONNECTOR TUBE HOSE 
  7. DISCONNECT HEATER INLET WATER HOSE 
  8. DISCONNECT FUEL TUBE SUB-ASSY (See  REPLACEMENT  ) 
  9. SEPARATE FRONT DRIVE SHAFT ASSY RH (4WD TYPE) (See  REMOVAL & INSTALLATION  ) 
  10. SEPARATE ENGINE MOUNTING INSULATOR ASSY RR (4WD TYPE) 
    1. Remove the 2 bolts and disconnect the engine mounting insulator.
    Fig 1: Removing Engine Mounting Insulator
    G03033043Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. REMOVE ENGINE MOUNTING BRACKET RR (4WD TYPE) (See  REPLACEMENT  ) 
  12. REMOVE INTAKE MANIFOLD (See  REPLACEMENT  ) 
  13. DISCONNECT ENGINE WIRE 
  14. REMOVE INTAKE MANIFOLD INSULATOR NO.1 
  15. REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO.1 
  16. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSY (See  REPLACEMENT  ) 
  17. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSY 
  18. REMOVE CHAIN SUB-ASSY (See  CHAIN (2AZ-FE)  ) 
  19. REMOVE NO.2 CAMSHAFT (See  OVERHAUL  ) 
  20. REMOVE CAMSHAFT (See  OVERHAUL  ) 
  21. REMOVE CAMSHAFT BEARING NO.2 
  22. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSY 
  23. REMOVE CYLINDER HEAD SUB-ASSY 
    1. Using a 10 mm Bi-hexagon wrench, uniformly loosen the 10 bolts in the sequence shown in the illustration. Remove the 10 cylinder head bolts and plate washers.
    NOTE:
    • Be careful not to drop washers into the cylinder head.
    • Head warpage or cracking could result from removing bolts in an incorrect order.
    Fig 2: Identifying Removal Sequence Of Cylinder Head Bolts
    G03033044Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. REMOVE CYLINDER HEAD GASKET 
  25. INSPECT CYLINDER HEAD SET BOLT (See  OVERHAUL  ) 
  26. INSTALL CYLINDER HEAD GASKET 
    1. Place a new gasket on the cylinder block surface with the Lot No. stamp upward.
    NOTE:
    • Remove any oil from contact surface.
    • Be careful of the installation direction.
    • To avoid damage to the gasket, place the cylinder head on the gasket carefully.
    Fig 3: Installing New Gasket On Cylinder Block Surface With Lot No Stamp Upward
    G03033045Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. INSTALL CYLINDER HEAD SUB-ASSY 

    HINT:

    The cylinder head bolts are tightened in 2 progressive steps.

    1. Apply a light coat of engine oil to the bolt threads and the area beneath the bolt heads that come in contact with the washers.
    2. Install the bolts and plate washers to the cylinder head.
      NOTE: Do not drop the washers into the cylinder head.
    3. Using a 10 mm bi-hexagon wrench, uniformly tighten the 10 bolts in the sequence shown in the illustration.
      1. Torque: 79 N.m (806 kgf.cm, 58 ft.lbf) 
      Fig 4: Identifying Tightening Sequence Of Cylinder Head Bolts
      G03033046Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Mark the front side of the cylinder head bolt with paint.
    5. Retighten the cylinder head bolts 90° in the sequence shown in the illustration.
    6. Check that the painted mark is now at a 90° angle to the front.
    Fig 5: Identifying Retightening Angle Of Cylinder Head Bolt
    G03033047Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSY 
    1. Torque: 9.0 N.m (92 kgf.cm, 80 in. Ibf) 
  29. INSTALL CAMSHAFT BEARING NO.2 
  30. INSTALL CAMSHAFT (See  OVERHAUL  ) 
  31. INSTALL NO.2 CAMSHAFT (See  OVERHAUL  ) 
  32. INSTALL CHAIN SUB-ASSY (See  CHAIN (2AZ-FE)  ) 
  33. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSY 
  34. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSY 
    1. Install a new gasket and the exhaust manifold convert with the 5 nuts. Uniformly tighten the nuts in the sequence shown in the illustration.
      1. Torque: 37 N.m (337 kgf.cm, 27 ft.lbf) 
      Fig 6: Identifying Tightening Sequence Of Exhaust Manifold Converter Bolts
      G03033048Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the No. 1 and No. 2 exhaust manifold stays with the 2 bolts and 2 nuts.
      1. Torque: 44 N.m (449 kgf.cm, 32 ft.lbf) 
      Fig 7: Installing Exhaust Manifold Stays
      G03033049Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  35. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO.1 
    1. Torque: 12 N.m (122 kgf.cm, 9 ft.lbf) 
  36. INSTALL INTAKE MANIFOLD INSULATOR NO.1 
  37. INSTALL ENGINE WIRE 
  38. INSTALL INTAKE MANIFOLD (See  REPLACEMENT  ) 
  39. INSTALL ENGINE MOUNTING BRACKET RR (4WD TYPE) (See  REPLACEMENT  ) 
  40. INSTALL ENGINE MOUNTING INSULATOR ASSY RR (4WD TYPE) 
    1. Install the mounting insulator with bolts.
      1. Torque: 75 N.m (765 kgf.cm, 55 ft.lbf) 
    Fig 8: Installing Engine Mounting Insulator
    G03033050Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  41. INSTALL FRONT DRIVE SHAFT ASSY RH (4WD TYPE) (See  REMOVAL & INSTALLATION  ) 
  42. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSY 
    1. Torque: 9.0 N.m (92 kgf.cm, 80 in.lbf) 
  43. CONNECT FUEL TUBE SUB-ASSY (See  REPLACEMENT  ) 
  44. INSTALL FRONT SUSPENSION BRACE SUB-ASSY UPPER CENTER 
    1. Torque: 80 N.m (816 kgf.cm, 59 ft.lbf) 
  45. ADD ENGINE OIL 
  46. ADD COOLANT (See  REPLACEMENT  ) 
  47. ADD TRANSFER OIL (4WD TYPE) 
    1. Install a new gasket and the filler plug.
      1. Torque: 49 N.m (500 kgf.cm, 36 ft.lbf) 
  48. CHECK FOR OIL LEAKS 
  49. CHECK FOR ENGINE COOLANT LEAKS (See  REPLACEMENT  ) 
  50. INSPECT FOR FUEL LEAKS 
  51. CHECK IDLE SPEED AND IGNITION TIMING (See  ENGINE (2AZ-FE)  ) 
  52. INSPECT CO/HC (See  ENGINE (2AZ-FE)  ) 
  53. CHECK ABS SPEED SENSOR SIGNAL 
  54. INSPECT FRONT WHEEL ALIGNMENT (See  ADJUSTMENT  ) 
scientia non olet · About LEMON Manuals